1988 Ranger 2.9 to 1992 Explorer 4.0 SWAP Write-up


abaryth

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4.0 Swap - 1992 Explorer 4.0 Auto 4x4 to 1988 Ranger 2.9 4x4
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What you will need:

4.0 Engine
Engine Harness
ECC Harness
ECC
EDIS Module
Power distribution box (underhood)
Intake w/MAF sensor
Sensor on firewall w/vacuum line
Fuel line quick disconnects that fit the 4.0 (off most Fords at Pull-a-Part)
4.0 Throttle Cable


Engine

The installation of the engine itself is quite straight forward. Remove the 2.9 with ECC and both harnesses and install the 4.0 in its place. The mounts, tranny, exhaust, radiator/heater hoses all mate together without hassle. The fuel lines from the 92 explorer do not mate with the 2.9 ranger lines. I cut the quick connects off of the ranger lines and trimed the line length appropriately. I then went to Pull-a-part and grabed the right size connectors from a Taurus and another Ranger. Heat up the fitting with a torch and insert it into the nylon fuel line. When it cools it's solid. I added a small hose clamp for added saftey. Make sure you put the retainer clips back on the connection. (TEST THIS FOR LEAKS WITHOUT STARTING THE ENGINE, IT'S RIGHT NEXT TO YOUR EXHAUST MANIFOLD AND COULD CAUSE A FIRE IF DONE INCORRECTLY)...

Wiring the 4.0

Starter - I retained my 2.9 starting system using the original starter with external solenoid. You want to use the 4.0 distribution box's fused link (60AMP, big green wire). Remove your BLK/ORG wire from the + terminal on the starter solenoid and connect it to this GRN wire. Connect the Large BLK wire with the ring terminal comming from the distribution box to the positive side of the starter solenoid. I then bypassed the clutch switch in the Ranger by connecting a wire from one of the RED wires on the clutch switch (under the dash on the clutch master cylinder) to the RED/LT BLU (goes to the small terminal on the starter solenoid) wire at the drivers side firewall. You should now be able to crank the engine over.

Mount the ECC in the same position as the 2.9 and run the 4.0 wiring harness through the firewall as it was on the 2.9. Connect it to the engine harness and connect the 4 PIN Black connector to the 4 PIN connector on the power distribution box which should be mounted on the passenger side inner fender. Mount and connect the EDIS module and the module with vacuum line. The only wires needed to run off of the distribution box are the GRN one and the ones in the 4 PIN connector (fuel and ECC relay). All others can be used for accesories (lights, etc). I just left 8 inches on each wire and removed the fuses for those links so as not to short things out.

Now you should have a big mess of connectors from your original setup on the driver side firewall and a mess of connectors for the 4.0 wiring harness. None of these are direct plug and play from the '88 2.9 to '92 4.0. Sorry! This is where the majority of the 4.0 swap write-ups have failed at least for these years. Yes, you can figure it out by staring at both wiring diagrams but it can be difficult. Here's what I did to make the bitch run.

Explorer--->Ranger
RED/LT GRN \___-----> RED/LT GRN (powers harness/ECC)
RED/LT GRN /
PNK/BLK ----------------> PNK/BLK (on a 1 PIN black connector)(Fuel Pump +12v)

You now need to ground the GRY/YEL wire in the 2 PIN black plug on the end for your 4.0 harness. Now when you turn your ignition on you should hear the relays click on and the fuel pump turn on. Fire that bitch up! There are numerous other wires that need to be attached but this is all you'll need to get going.

Also to get the alternator charging with the 4.0 harness you need to run the LT GRN/RED over to the firewall harness LT GRN/RED. I'll make a thought out post with ALL the wiring colors and splices needed for this swap at a later date.. Also keep in mind that the engine temp sensor and tachometer will not work correctly. I used the oil and temp sensors out of the 2.9 and have yet to find a fix for the tach which reads too high. A tach for DIS is around $66 but I'll try resistors first just to see if it's possible.

Look at the conversion chart on my Photobucket to make the remaining connections.


Here is a link to all wiring diagrams and firewall wiring conversion charts that I used to do my swap as well as pictures of the install taking place.

http://s268.photobucket.com/albums/jj28/abaryth/Ranger_Wheelin/engine swap/


Here are the wiring diagrams:

4.0 Explorer Engine (1992)



2.9 Ranger/Bronco II (1988)




Here's a chart someone did for their BII 4.0l swap. It helped me with the Ranger swap as well as it's very similar.



Hope this helps someone... Feel free to ask questions!
 
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okietheranger

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u useing the 2.9 rad? does it ever get hot?
 

abaryth

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2.9 rad

I've been driving it for a week now in the snow and ice and it seems to run a bit hotter than the 2.9 did but nothing too serious. I'm using the clutch fan and a 2 speed electric BMW fan pushing in front.. if it ever does get hotter than it is at NOT then I'll just kick the electric on... Ususally only gets hotter than normal in low gears while wheeling.


2.9 radiator: 18x17x1"
4.0 mt radiator 18x17.75x1"
4.0 at radiator 18x17.75x2"
 
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abaryth

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tranny

For now yes.. Everyone says they are weaker and won't stand up to the 4.0l's increased torque but I'm willing to give it a try. If it goes, it goes. I know 2 people that have been running 2.9 trans in their 4.0 swaps for some time without failure. I also read somewhere that they are pretty much the same except for the lower gearing.. I haven't done much hardcore wheeling with it yet on the swap so we'll see!
 

akagomer

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Would you e-mail me a copy of the wiring drawing that shows the changes, the one you have he is not clear,,,My e-mail is dapatt2002@yahoo.com Thanks Bunches
 

slow96gt

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on your 92 harness was it a four pin connector going to the fuel pump with two pinks a blacm and gray wire? im trying to find the fuel pump connector on my 92 ex harness
 

camobancher88

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ok so i did a 4.0 swap from a 92 explorer onto my 88 ranger... i used everything from the 4.0. dash all wiring EVERYTHING!!!!!!!! have most of it figured out other then how to make the dual fuel pumps to wire into the 8 pin connection on the 4.0 harness... i aready have learned that the fuel gauge wont work... but how about to power the pump... am i gonna have to use a newer tank...
 

tcbaklash

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My 2.9 came stock with the Mazda transmission, which was standard with the 4.0 and 2.3. There's a few out there with the same setup, so I would check to make absolute certain that you're transmission is, or is not a Mitsubishi. Easiest way to check is the door panel sticker code "M", or slide under the truck and look for bolts on the bottom of the tranny. If it doesn't have them, it's a Mazda.
 
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